B5 S4, operation money pit. Forever evolving, never ending.

[Spiff325iS]

This is awesome and makes me reconsider this car.. or an all road- keep it up!

[Exodus_2pt0]

I know I said I was done until Monday, but we got back early.

Intercooler is done (minus bumper fitment, going to run it for a few days without the bumper just in case I have any issues), exhaust is mounted.

Fluids, and some minor loose ends to tie up. Maiden voyage should be tomorrow. I'm glad I took those extra two days, this is definitely a significant amount of work.

[Exodus_2pt0]

Snuck out this morning to mock up the pipes. Needs some tweaking, but at least this way no critters will climb into anything. Not sure what 25psi would do to a chipmunk....

[Exodus_2pt0]

Yup, drop the belly pan, pop the side tabs on the bumper (yank), remove grills, remove 2 allen bolts, remove bumper, disconnect a small cluster of plugs, pop radiator hoses (quick tabs, no clamps), remove 9 bolts, remove core support. Done, takes about 10 minutes.

[HennaE30]

Dont you have to pull the whole front end to do a timing belt on those

You do, but he said he thought it was easy.

[Kevinl]

Dont you have to pull the whole front end to do a timing belt on those

[Exodus_2pt0]

Screw it, up with the photos.

Ready to go back home


This is where I stopped. I got the one pipe mounted, and it needs to go to the top of the intercooler. Didn't bother to watch the video until I came inside.


I can't wait to take it for a drive. Ended up holding off on the timing belt. When I pulled the covers the cam seals are seeping, which I don't have. So, since I technically am still 10k away from the recommended mileage and the belt isn't oil saturated, I'm holding off for a little while. (At least until I get seals to replace the leaky ones) Famous last words, I know.

[Exodus_2pt0]

Going back together. Mounting the intercooler, and need to install the exhaust, add fluids and bam.

Had a "oh shit" moment though. After everything was in I decided to try out the clutch. I didn't break a line so it doesn't need to be bled. Pressed it, and it went to the floor, only to return about 3 inches. Pressure felt good though.

So as I'm thinking "shit something is hanging up, I'm fucked, fuck this I quit." I decided to pull the pedal up and try again. Feels great! Must have been the SAC mecha ism settling in. I has photos to upload, but I'm hanging out with the Mrs. this evening, and we will be on the river all day tomorrow. Will finish this POS up on Monday.

[Exodus_2pt0]

Just a little motivational video. This guy is running almost the exact setup I will be.

[Exodus_2pt0]

Stripped banjo bolt? No problem, heli-coil that bitch. (Wastegate reference)

Stop by Napa. Bolt is a m8X1.0 bolt. They only have m8X1.25 kits in stock, won't have a m8x1.0 until Tuesday.

Skip to 0:24


So, re-thread banjo bolt for 1.25 it is, drill, tap, install helicoil and problem solved.

Engine is going in currently, taking photo's along the way.

[Exodus_2pt0]

That's the one I went with. Against the internet's best suggestions.

[TheTacoMan]

My brother has a front mount on his allroad, seemed to help the heat soak issues aton. Although at the cost of A/c performing worse at low speed.

[Exodus_2pt0]

So motor is out and turbo's installed. Turbo's gave me a fight, and I need to get a helicoil kit in the morning. The banjo bitting for wastegate pressure on the compressor of the drivers side turbo is stripped. Oh well, used turbo's.

I also pulled the flywheel and clutch but didn't install the new one yet.

Tomorrow morning I should be able to knock the rest out relatively quick and start putting it back together. Exhaust showed up, no intercooler yet. Rescheduled for tomorrow delivery.



Speaking of mounts, both of mine looked like this....



Twin muffler, dual 2.5" exhaust. Should sound nice but not loud.


Almost forgot the comparison shot.

[HennaE30]

Yessir. I turned wrenches for a living for about 10 years, I actually prefer to work alone.

Put on my music, and get to it.

Funny thing is this is the first time I've really enjoyed a large project since before I ever earned a living off of it. I came to hate it when I had to do it for a living.

I am the same way, get the music going and get wrenching. I'm just impressed at how quick that came out doing that by yourself. Looks good dude, mucho excited to see how it turns out.

[Exodus_2pt0]

Yessir. I turned wrenches for a living for about 10 years, I actually prefer to work alone.

Put on my music, and get to it.

Funny thing is this is the first time I've really enjoyed a large project since before I ever earned a living off of it. I came to hate it when I had to do it for a living.